Regeneration of an acidic catalyst by borane addition

ABSTRACT

A method of regenerating an acidic catalyst is described. A borane compound is contacted with an acidic catalyst that contains conjunct polymer, which releases the conjunct polymer from the acidic catalyst. The acidic catalyst can then be re-activated with acid. The conjunct polymer can be separated from the borane compound, and the borane compound can be recycled.

BACKGROUND OF THE INVENTION

Commercially, the alkylation of isoparaffins is performed by acids such as sulfuric acid and hydrofluoric acid. Conjunct polymer (acid soluble oils, (ASO) also known as red oil) forms as a byproduct of the alkylation reaction, as well as other hydrocarbon reactions. When too much conjunct polymer is present, the acid catalyst loses its effectiveness. The acid must be replaced with stronger acid, or the conjunct polymer must be removed in order to reactivate the catalyst. With sulfuric acid as the catalyst, the ASO is burned, and with hydrofluoric acid, the hydrofluoric acid is distilled away from the ASO. Sulfuric acid and hydrofluoric acid are hazardous and corrosive, and their use in industrial processes requires a variety of environmental controls.

There has been a move to replace the use of sulfuric acid and hydrofluoric acid with more environmentally friendly materials.

One such process utilizes acidic ionic liquids as catalysts in hydrocarbon conversion processes, such as alkylation, isomerization, disproportionation, and oligomerization. Conjunct polymers are byproducts of the hydrocarbon reaction using ionic liquids, and they form a complex with the ionic liquid catalyst. The ionic liquid catalyst loses its effectiveness over time as the amount of conjunct polymer increases. It must then either be replaced or regenerated. Because ionic liquids are typically fairly expensive, processes for regenerating the ionic liquid catalysts are needed.

A variety of methods for regenerating ionic liquids have been developed. The ionic liquid containing the conjunct polymer could be contacted with a reducing metal (e.g., Al), an inert hydrocarbon (e.g., hexane), and hydrogen and heated to about 100° C. The conjunct polymer will be transferred to the hydrocarbon phase, allowing for the conjunct polymer to be removed from the ionic liquid phase. See e.g., U.S. Pat. Nos. 7,651,970; 7,825,055; 7,956,002; and 7,732,363.

Another method involves contacting the ionic liquid containing the conjunct polymer with a reducing metal (e.g., Al) in the presence of an inert hydrocarbon (e.g. hexane), but in the absence of added hydrogen, and heating to about 100° C. The conjunct polymer will be transferred to the hydrocarbon phase, allowing for the conjunct polymer to be removed from the ionic liquid phase. See e.g., U.S. Pat. No. 7,674,739.

Still another method of regenerating the ionic liquid involves contacting the ionic liquid containing the conjunct polymer with a reducing metal (e.g., Al), HCl, and an inert hydrocarbon (e.g. hexane), and heating to about 100° C. The conjunct polymer will be transferred to the hydrocarbon phase, allowing for the CP to be removed from the IL phase. See e.g., U.S. Pat. No. 7,727,925.

The ionic liquid can be regenerated by adding a homogeneous metal hydrogenation catalyst (e.g., (PPh₃)₃RhCl) to the ionic liquid containing the conjunct polymer and an inert hydrocarbon (e.g. hexane). Hydrogen would be introduced, and the conjunct polymer would be reduced and transferred to the hydrocarbon layer. See e.g., U.S. Pat. No. 7,678,727.

Another method for regenerating the ionic liquid involves adding HCl, isobutane, and an inert hydrocarbon to the ionic liquid containing the conjunct polymer and heating to about 100° C. The conjunct polymer would react to form an uncharged complex, which would transfer to the hydrocarbon phase. See e.g., U.S. Pat. No. 7,674,740.

The ionic liquid could also be regenerated by adding a supported metal hydrogenation catalyst (e.g. Pd/C) to the ionic liquid containing the conjunct polymer and an inert hydrocarbon (e.g. hexane). Hydrogen would be introduced and the conjunct polymer would be reduced and transferred to the hydrocarbon layer. See e.g., U.S. Pat. No. 7,691,771.

Still another method involves adding a basic reagent that displaces the conjunct polymer and is part of the regeneration of the catalyst. The basic reagents are described as nitrogen-containing compounds such as amines, pyridinium compounds, or pyrrolidinium compounds. For example, a suitable substrate (e.g. pyridine) is added to the ionic liquid containing the conjunct polymer. After a period of time, an inert hydrocarbon would be added to wash away the liberated conjunct polymer. In another example, the ionic liquid precursor [butylpyridinium][Cl] would be added to the ionic liquid (e.g. [butylpyridinium][Al₂Cl₇]) containing the conjunct polymer followed by an inert hydrocarbon. After a given time of mixing, the hydrocarbon layer would be separated, resulting in a regenerated ionic liquid. The solid residue would be converted to catalytically active ionic liquid by adding AlCl₃. See, e.g., U.S. Pat. Nos. 7,737,363, and 7,737,067.

Another method involves adding the ionic liquid containing the conjunct polymer to a suitable substrate (e.g. pyridine) and an electrochemical cell containing two aluminum electrodes and an inert hydrocarbon. A voltage would be applied and the current measured to determine the extent of reduction. After a given time, the inert hydrocarbon would be separated, resulting in a regenerated ionic liquid. See, e.g., U.S. Pat. No. 8,524,623.

All of these regeneration approaches have drawbacks. Many of them cannot achieve above 90% conversion of the conjunct polymer, which then builds up in the process. Of those that can provide high levels of conversion, hydrogenation of the spent ionic liquid with supported (e.g., U.S. Pat. No. 7,691,771) and unsupported (e.g., U.S. Pat. No. 7,678,727) hydroprocessing catalysts may result in the active catalytic metals being extracted into the ionic liquid phase. Many catalyst supports also react irreversibly with the chloroaluminate anion of the ionic liquid. Although the use of metallic aluminum for regeneration (e.g., U.S. Pat. No. 7,995,495) is effective, it introduces undesirable solids handling issues into the refinery. Finely divided aluminum is pyrophoric and presents safety issues in a refining environment. This approach also results in the creation of additional AlCl₃, which has to be removed from the ionic liquid phase (e.g., U.S. Pat. No. 7,754,636) to avoid building up to a molar ratio relative to the ionic liquid cation at which solids will start coming out of solution and cause plugging issues. Electrochemical approaches (e.g., U.S. Pat. No. 8,524,623) are not economically viable at commercial scales.

Therefore, there remains a need for additional methods of regenerating ionic liquids used as catalysts in reactions.

SUMMARY OF THE INVENTION

One aspect of the invention involves a method for regenerating deactivated acidic catalyst containing conjunct polymer. In one embodiment, the method includes contacting the deactivated acidic catalyst containing the conjunct polymer with at least one borane compound in a regeneration zone under regeneration conditions, the acidic catalyst selected from the group consisting of sulfuric acid, hydrofluoric acid, trifluoromethanesulfonic acid, phosphoric acid, boron trifluoride, and acidic ionic liquids, the conjunct polymer reacting with the at least one borane compound resulting in a catalyst phase and an organic phase containing the conjunct polymer and at least one boryl compound.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one embodiment of a method for regenerating deactivated acidic ionic liquid catalyst containing conjunct polymer complex according to the present invention.

FIG. 2 illustrates another embodiment of a method for regenerating deactivated acidic ionic liquid catalyst containing conjunct polymer complex according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

It has been discovered that deactivated acidic catalysts containing conjunct polymer can be regenerated without using a reagent that contains no metals and that reacts under mild conditions. In some embodiments, the reagent can be easily separated by gravity from the ionic liquid. When a liquid reagent is used, the process does not produce any net solids that have to be handled or treated. When solvents are used with liquid reagent, the liquid reagent can be easily separated from the solvent. In addition, the mild conditions under which the process can be performed may result in lower operating costs than processes requiring harsher conditions. The mild operating conditions may also result in lower capital costs due to the ability to use less expensive materials of construction.

By deactivated acidic catalysts containing conjunct polymer, we mean acidic catalysts that have been used in hydrocarbon conversion processes, and in which conjunct polymers have formed. Acidic catalysts which form conjunct polymers in hydrocarbon conversion processes include sulfuric acid, hydrofluoric acid, trifluoromethanesulfonic acid (triflic acid), phosphoric acid, boron trifluoride, and acidic ionic liquids. By conjunct polymer, we mean the olefinic, conjugated cyclic hydrocarbons that form as a byproduct of various hydrocarbon conversion processes, including but not limited to alkylation, oligomerization, isomerization, disproportionation, and reverse disproportionation.

By acidic ionic liquid, we mean an ionic liquid capable of catalyzing reactions typically carried out with an acid. As known in the art, acids such as sulfuric acid and hydrofluoric acid are often used to catalyze these reactions. These reactions include, e.g. alkylation, oligomerization, isomerization, disproportionation, and reverse disproportionation. Oftentimes the acids employed in these reactions have Hammett acidity functions (H₀) less than 7, or less than 5, or less than 3, or less than 0, or less than −3, or less than −5, or less than −7, or less than −9. If the ionic liquid does not possess an acidic proton in its structure (e.g. 1-butyl-3-methylimidazolium heptachloroaluminate), addition of an exogenous acid is acceptable, provided the Hammett acidity function (H₀) of the added acid is less than 7 within the ionic liquid, or less than 5, or less than 3, or less than 0, or less than −3, or less than −5, or less than −7, or less than −9. Acidic chloroaluminate-containing ionic liquids have a molar ratio of Al to cation greater than 1.

By the term about, we mean within 10% of the specified value, or within 5%, or within 1%.

The contact of a borane compound with an acidic catalyst that contains conjunct polymer releases the conjunct polymer from the acidic catalyst. When the acidic catalyst is an ionic liquid, the ionic liquid can then be re-activated with acid. Other acidic catalyst may also require reactivation. The conjunct polymer can be separated from the borane compound, and the borane compound can be recycled.

The borane reacts with the acid sites of the acidic catalyst. For example, the borane will react with acid sites in a halometallate ionic liquid to form a boryl halide. The acid sites that were binding the conjunct polymer are no longer present, which allows the conjunct polymer to be removed.

The deactivated acidic catalyst and the borane compound are contacted for a period of time sufficient to allow the conjunct polymer to react with the borane compound. This will typically take in the range of about 5 sec to about 1 hr, or about 1 min to about 45 min, or about 1 min to about 30 min, or about 1 min to about 15 min.

The contacting typically takes place at a temperature in the range of from about −20° C. to the degradation temperature of the acidic catalyst. For ionic liquids, the upper limit is the decomposition temperature of the ionic liquid. A typical temperature range is about 20° C. to about 80° C. In some embodiments, the contacting takes place at room temperature. In other embodiments, the contacting takes place at about 40° C. to about 80° C., or about 70° C.

The pressure is typically ambient pressure, although higher or lower pressures could be used if desired.

In some embodiments, the reaction is conducted under an inert gas so that hydrolysis of the borane does not occur. When the acidic catalyst is an ionic liquid, the ionic liquid may also hydrolyze, so these reactions are desirably conducted under an inert gas. Suitable inert gases include, but are not limited to, nitrogen, helium, neon, argon, krypton, and xenon.

In some embodiments, the volume ratio of the solvent to the deactivated acidic ionic liquid is in a range of about 0.25:1 to about 10:1.

In some embodiments, the molar ratio of the borane compound to the conjunct polymer complex is in a range of about 0.5:1 to about 5:1, or about 2:1 to about 3:1. In some embodiments, the borane compound can be present in excess of the amount needed for reaction with the conjunct polymer, and the excess borane compound can act as a solvent. In these cases, the molar ratio of the borane compound to the conjunct polymer is more than 5:1, e.g., in the range of 10:1 to about 1000:1.

The contacting can take place in any suitable process, such as solvent extraction, contacting in one or more mixer/settlers.

The reaction will proceed simply by contacting the borane compound with the liquid acidic catalyst. However, the mixture can be stirred to increase the contact between the borane compound and the acidic catalyst. Stirring is particularly useful when the acidic catalyst is an ionic liquid.

The contacting step may be practiced in laboratory scale experiments through full scale commercial operations. The process may be operated in batch, continuous, or semi-continuous mode. The contacting step can take place in various ways, with both countercurrent and co-current flow processes being suitable. The order of addition of the reactants is not critical. For example, the reactants can be added individually, or some reactants may be combined or mixed before being combined or mixed with other reactants.

After contacting the acidic catalyst and the borane compound, two phases result, a catalyst phase containing the acidic catalyst and an organic phase containing the conjunct polymer and the boryl compound and solvent, if present. In some embodiments, the phases will separate due to the density difference between the two phases. In other embodiments, other separation processes may be needed. In some embodiments, the conjunct polymer can be decanted away. Decanting can be suitable if there is enough conjunct polymer present and it separates from the acidic catalyst.

When the acidic catalyst is an ionic liquid, the ionic liquid can be reactivated by adding an appropriate acid. The reactivated acidic catalyst can then be recycled to the hydrocarbon conversion process. Other acidic catalyst may also need to be reactivated by adding an appropriate acid.

The organic phase containing the conjunct polymer and the boryl compound can be treated as well. The conjunct polymer can be separated from the boryl compound, and the boryl compound can be regenerated. The regenerated borane can be recycled and reused to contact with the deactivated acidic catalyst.

The boryl compound can be chemically reduced to regenerate the borane compound. One method of regeneration is reaction with one or more compounds containing hydrogen, such one or more as metal hydrides. The reaction can take place in a suitable solvent, such as tetrahydrofuran (THF), or toluene. The boryl compound is converted back to the borane compound and a metal salt byproduct. Suitable metal hydrides include, but are not limited to, LiH, NaH, CaH₂, NaAlH₄, LiAlH₄, KH, NaBH₄, diisobutylaluminum hydride, and the like.

The borane regeneration reaction can take place in a few hours at temperatures in the range of about 25° C. to about 60° C., depending on the metal hydride and solvent used.

When the borane compound is mixed with a solvent for the contacting step, the solvent can be recovered before or after separating the conjunct polymer from the boryl compound. The recovered solvent can be recycled and reused in the process.

In some embodiments, the conjunct polymer is separated from the solvent and boryl compound at the same time. The separation can take place in a fractionation column, for example. The conjunct polymer may also be adsorbed onto a solid adsorbent such as alumina or activated carbon, and later removed by combustion for heat recovery.

Alternatively, if the solvent is compatible with the subsequent reaction regenerating the borane, the solvent may not be removed. In those situations, the conjunct polymer is separated from the solvent and boryl compound mixture, and the boryl compound is regenerated while in the solvent. The solvent and regenerated borane can then be recycled and reused.

In some embodiments, the separation of the conjunct polymer from the boryl compound may not be complete because the boryl compound may co-boil with the lower molecular weight conjunct polymer making complete removal difficult.

The regenerated borane can be separated from the metal salt byproduct and recycled back for use in the process. Suitable separation processes include, but are not limited to, filtration, and decanting.

In another embodiment, the acidic catalyst containing conjunct polymer is passed through a resin containing borane moieties. Suitable resins include, but are not limited to, polystyrene and polyester. The borane moieties react with the acid sites, and the conjunct polymer can be extracted into an organic phase. The ionic liquid is regenerated by adding acid.

In one embodiment, the regeneration process is a solvent extraction process. For ease of discussion, the use of deactivated acidic ionic liquid in the solvent extraction process will be described. However, as will be understood by those of skill in the art, other acidic catalysts which form conjunct polymers could also be used.

In the solvent extraction method, a solvent and a borane compound are added to the ionic liquid containing conjunct polymer. The solvent and the borane compound can be pre-mixed and added together, or they can be added separately, either at the same time or sequentially. Solvent is not always necessary, but it will maximize recovery, removal, and separation of the conjunct polymer.

The borane compound reacts with the free acid and acid sites tied up in the conjunct polymer. After these acid sites are quenched, the conjunct polymer migrates from the ionic liquid phase to the organic phase and can be extracted.

In a system without stirring or after stirring is ended, the components can separate into two phases based on the density difference between the ionic liquid phase and the organic phase which contains the conjunct polymer. The ionic liquid will settle to the bottom, and the borane and conjunct polymer will be on top of the ionic liquid layer. Increasing the top layer with additional solvent will increase conjunct polymer recovery.

The deactivated ionic liquid, the solvent, and the borane compound are contacted long enough for the conjunct polymer to react with the borane compound, typically about 5 sec to about 1 hr. The deactivated ionic liquid, the solvent, and the borane compound are typically mixed while being contacted.

The deactivated ionic liquid, the solvent, and the borane compound are typically contacted at a temperature in the range of from about −20° C. to less than the decomposition temperature of the ionic liquid, or about 20° C. to about 80° C., or about 40° C. to about 80° C. In some embodiments, the contacting takes place at temperatures above room temperature, e.g., about 70° C.

The mixture is then allowed to separate into two phases: an ionic liquid phase and a hydrocarbon phase. In some embodiments, separation occurs due to the density difference between the ionic liquid phase and the hydrocarbon phase. Separation typically takes on the order of a few minutes to hours; it is generally less than about 1 hr.

The solvent layer is decanted from the ionic liquid. The ionic liquid can be further washed with solvent (either the same solvent used in the extraction or a different one), if desired. As the reaction occurs, the conjunct polymer is extracted into the solvent layer. Volatiles are removed from the organic layer to isolate the conjunct polymer as a viscous oil. In one embodiment, the volatiles can be removed by heating the material under reduced pressure.

In some embodiments, the addition of an acid or an acid precursor reactivates the ionic liquid following removal of the conjunct polymer. Suitable acids and acid precursors include, but are not limited to, HCl, tert-butyl chloride, or 2-chlorobutane. The acid precursor can be any molecule that will break down to form the acid. Reactivation of the ionic liquid with acid or acid precursor typically takes about 5 sec to about 30 min. It can be done at a range of temperatures. For convenience, it is typically done at the same conditions as the hydrocarbon conversion process which generates the conjunct polymer.

The ionic liquid containing the conjunct polymer can be pre-treated before it is contacted with the borane compound. The pretreatment can be used to remove any free acid, such as HCl, which might increase the consumption of the borane compound, and/or any dissolved solvent, which might associate with the conjunct polymer. The pretreatment can be in a fractionation column, for example.

The ionic liquid can be any acidic ionic liquid. There can be one or more ionic liquids. The ionic liquid comprises an organic cation and an anion. Suitable cations include, but are not limited to, nitrogen-containing cations and phosphorus-containing cations. Suitable organic cations include, but are not limited to:

where R¹-R²¹ are independently selected from C₁-C₂₀ hydrocarbons, C₁-C₂₀ hydrocarbon derivatives, halogens, and H. Suitable hydrocarbons and hydrocarbon derivatives include saturated and unsaturated hydrocarbons, halogen substituted and partially substituted hydrocarbons and mixtures thereof. C₁-C₈ hydrocarbons are particularly suitable.

The anion can be derived from halides, typically halometallates, and combinations thereof. The anion is typically derived from metal and nonmetal halides, such as metal and nonmetal chlorides, bromides, iodides, fluorides, or combinations thereof. Combinations of halides include, but are not limited to, mixtures of two or more metal or nonmetal halides (e.g., AlCl₄ ⁻ and BF₄ ⁻), and mixtures of two or more halides with a single metal or nonmetal (e.g., AlCl₃Br⁻). In some embodiments, the metal is aluminum, with the mole fraction of aluminum ranging from 0<Al<0.25 in the anion. Suitable anions include, but are not limited to, AlCl₄ ⁻, Al₂Cl₇ ⁻, Al₃Cl₁₀ ⁻, AlCl₃Br⁻, Al₂Cl₆Br⁻, Al₃Cl₉Br⁻, AlBr₄ ⁻, Al₂Br₇ ⁻, Al₃Br₁₀ ⁻, GaCl₄ ⁻, Ga₂Cl₇ ⁻, Ga₃Cl₃ ⁻, GaCl₃Br⁻, Ga₂Cl₆Br⁻, Ga₃Cl₉Br⁻, CuCl₂ ⁻, Cu₂Cl₃ ⁻, Cu₃Cl₄ ⁻, ZnCl₃ ⁻, FeCl₃ ⁻, FeCl₄ ⁻, Fe₃C₇ ⁻, PF₆ ⁻, and BF₄ ⁻.

The borane compound can be any borane compound having a reactive B—H bond. In some embodiments, the borane compound is an organoborane. There can be one or more boranes. Suitable borane compounds include, but are not limited to, boranes having the formulas: R₂BH or where each R is independently selected from hydrocarbons or halides, or B₂H₆, or combinations thereof. Examples of suitable boranes include 9-borabicyclo(3,3,1)nonane, trimesitylborane, trisec-butylborane, and diborane and the like. In some embodiments, the borane can be a borane-containing resin.

The solvent will depend on the acidic catalyst being regenerated. The solvent can be any solvent which is capable of forming a separate phase from the catalyst phase. There can be one or more solvents. Suitable solvents for halometallate ionic liquids include, but are not limited to, n-paraffins, isoparaffins, and cyclic paraffins, such as C₄ to C₁₀ paraffins, and aromatic solvents. If the ionic liquid is soluble in hydrocarbons, more polar solvents which are not miscible in the ionic liquid would be used. The use of organic solvents may be less desirable with oxidizing acids.

FIG. 1 illustrates one embodiment of the process. 100. For ease of discussion, the process will be described using tributylhexylphosphonium chloroaluminate ionic liquid (TBHP-Al₂Cl₇), 9-borabicyclo(3,3,1)nonane (9-BBN), and n-butane (nC₄) solvent. Other acidic catalysts, including acidic ionic liquids, borane compounds, and solvents could also be used, as would be understood by those skilled in the art.

The deactivated ionic liquid feed 105 is introduced into a reactive extraction zone 110. The ionic liquid is TBHP-Al₂C₇. The deactivated ionic liquid feed 105 contains [TBHP⁺][AlCl₄ ⁻/AlCl₃]+[H⁺][AlCl₄ ⁻]+[CPH⁺][AlCl₄ ⁻]

where [CPH⁺] represents the protonated conjunct polymer. A solvent/borane compound stream 115 is introduced into the reactive extraction zone 110 and flows countercurrent to the deactivated ionic liquid feed 105. The solvent/borane compound stream 115 contains [9-BBN]+[nC₄].

The deactivated ionic liquid feed 105 reacts with the 9-BBN to form a boryl chloride. Although not wishing to be bound by theory, it is believed that a reaction occurs between the 9-BBN and the acid sites tied up with the conjunct polymers. When the conjunct polymer is no longer protonated, it becomes an organic-like molecule (no longer charged), so it is easily transferred to the organic phase. [9-BBN]+[CPH⁺][AlCl₄ ⁻]→[B—Cl]+[CP]+[AlCl₃]+[H₂].

The ionic liquid phase with the conjunct polymer removed 120 can be separated from the hydrocarbon phase by taking advantage of the fact that it has a higher density than the hydrocarbon phase 125.

The ionic liquid phase 120 contains dissolved/suspended AlCl₃, which is reactivated by adding an acid 135, such as HCl, in zone 130 to restore the active acid site: [AlCl₃]+HCl→[H⁺][AlCl₄ ⁻].

The re-activated ionic liquid 140 contains [TBHP⁺][AlCl₄ ⁻/AlCl₃]+[H⁺][AlCl₄ ⁻].

The re-activated ionic liquid 140 can then be recycled back to the hydrocarbon process.

The hydrocarbon phase 125 contains the B—Cl, solvent, conjunct polymer, hydrogen, and any unreacted 9-BBN. [B—Cl]+[nC₄]+[CP]+[H₂]+[9-BBN].

The B—Cl in the hydrocarbon phase 125 is reacted to regenerate the 9-BBN in a reaction zone 145. One method of reacting the B—Cl is with reducing agents that contain H⁻, such as metal hydrides 150. [B—Cl]+MH->[9-BBN]+[MCl].

The effluent 155 from the reaction zone 145 contains the regenerated 9-BBN, the solvent, the conjunct polymer, and the metal halide. [9-BBN]+[nC₄]+[CP]+[MCl].

The effluent 155 from the reaction zone 145 can be sent to a separation zone 160 where the solvent and 9-BBN are separated from the metal halide 165 and conjunct polymer 170. The solvent and 9-BBN can be recycled to the extraction zone 110 as stream 115.

FIG. 2 illustrates another embodiment of the treatment of the hydrocarbon phase 125. As described above, the hydrocarbon phase 125 contains the B—Cl, solvent, conjunct polymer, hydrogen, and any unreacted 9-BBN. In this embodiment, the hydrocarbon phase 125 is sent to a separation zone 180 where the solvent and any unreacted 9-BBN 185 are removed and recycled to the reactive extraction zone 110. Side stream 190 contains the B—Cl. Overhead stream 195 may contain hydrogen, which can be recovered. Bottoms stream 200 contains the conjunct polymer, which can be recovered for blending into a suitable refinery stream. Stream 190 is sent to reaction zone 205 where the boryl compound is regenerated. A metal hydride 210 is added to reaction zone 205 to convert the B—Cl to 9-BBN and byproduct metal chloride. The 9-BBN stream 215 can be combined with recycled solvent 185 and make-up solvent and/or 9-BBN 220 and recycled to the reactive extraction zone 110. The metal chloride 225 is removed.

EXAMPLES

Generation of Spent Ionic Liquid Catalyst:

Samples were generated in a continuous alkylation process in which 2-butenes were contacted with tributylhexylphosphonium heptachloroaluminate ionic liquid in the presence of isobutane and 2-chlorobutane. Contacting took place in a stirred 300 mL autoclave stirred at 1200 rpm. The mixture was continuously transferred to a gravity separator and recycled to the reactor. Flow rates and feed ratios varied over the course of the reaction which took place over several days to weeks for the various samples. At the end of each run, the heavy fraction containing ionic liquid was collected and stored under nitrogen. The % CP in each of the spent samples was determined by extraction and isolation of CP. The spent ionic liquid was mixed with water. The CP was extracted from the IL/water mixture with hexane. The hexane was removed on a rotary evaporator and the mass of the isolated CP was determined.

Example 1

Under a nitrogen atmosphere, hexane was added to spent TBHP-Al₂Cl₇ ionic liquid containing conjunct polymer followed by the addition of 9-BBN as a solution in hexane. After stirring in an autoclave for 1 hr at 70° C., the mixture was allowed to settle to separate the hexane layer and the ionic liquid layer. The hexane layer was decanted from the ionic liquid layer. The ionic liquid layer was further washed with pentane. Upon exposure to air, a white precipitate was formed which was filtered out of the hexane layer. The volatiles were removed from the hexane layer to isolate the conjunct polymer as a viscous oil (92% of the conjunct polymer was isolated). The isolated conjunct polymer is a similar molecular weight to conjunct polymer previously isolated using silane compounds. The addition of 2-chlorobutane to the ionic liquid layer restored the activity of the ionic liquid. The performance was similar to fresh ionic liquid, with a RONC of 95 for the regenerated ionic liquid and a RONC of 94 for the fresh ionic liquid, and with a butene conversion of 99% for both ionic liquids.

While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims. 

What is claimed is:
 1. A method for regenerating deactivated acidic catalyst containing conjunct polymer comprising: contacting the deactivated acidic catalyst containing the conjunct polymer with at least one borane compound in a regeneration zone under regeneration conditions, the acidic catalyst selected from the group consisting of sulfuric acid, hydrofluoric acid, trifluoromethanesulfonic acid, phosphoric acid, boron trifluoride, and acidic ionic liquids, the conjunct polymer reacting with the borane compound resulting in a catalyst phase and an organic phase containing the conjunct polymer and at least one boryl compound.
 2. The method of claim 1 further comprising: mixing an acid with the catalyst phase to reactivate the acidic catalyst; and recycling the reactivated acidic catalyst to a hydrocarbon conversion zone.
 3. The method of claim 2 further comprising separating the catalyst phase from the organic phase before mixing the acid with the catalyst phase.
 4. The method of claim 1 further comprising: chemically reducing the at least one boryl compound to regenerate the at least one borane compound.
 5. The method of claim 4 further comprising separating the at least one regenerated borane compound from the conjunct polymer.
 6. The method of claim 1 wherein contacting the deactivated acidic catalyst containing the conjunct polymer with the at least one borane compound comprises contacting the deactivated acidic catalyst containing the conjunct polymer with the at least one borane compound and a solvent, wherein the solvent is capable of forming a separate phase from the acidic catalyst.
 7. The method of claim 6 further comprising: chemically reducing the at least one boryl compound to regenerate the at least one borane compound; and separating the at least one regenerated borane compound and the solvent from the conjunct polymer.
 8. The method of claim 6 wherein a volume ratio of the solvent to the deactivated acidic catalyst containing the conjunct polymer is in a range of about 0.25:1 to about 10:1.
 9. The method of claim 6 wherein the solvent comprises a normal paraffin, an isoparaffin, or a cyclic paraffin having up to 10 carbon atoms, an aromatic, or the at least one borane compound.
 10. The method of claim 1 wherein a molar ratio of the at least one borane compound to the conjunct polymer is in a range of about 0.5:1 to about 5:1.
 11. The method of claim 1 wherein the deactivated acidic catalyst containing the conjunct polymer comprises the ionic liquid.
 12. The method of claim 11 wherein the regeneration conditions include a temperature in a range of from about −20° C. to less than a decomposition temperature of the ionic liquid.
 13. The method of claim 1 wherein contacting the deactivated acidic catalyst containing the conjunct polymer with the at least one borane compound further comprises mixing the deactivated acidic catalyst containing the conjunct polymer with the at least one borane compound.
 14. The method of claim 1 wherein the deactivated acidic catalyst containing the conjunct polymer is contacted with the at least one borane compound for between about 5 sec and about 1 hr.
 15. The method of claim 1 wherein the at least one borane compound comprises a compound having a formula R₂BH, where each R is independently selected from hydrocarbons or halides, or B₂H₆, or combinations thereof.
 16. The method of claim 1 further comprising pretreating the deactivated catalyst containing the conjunct polymer before contacting the deactivated acidic catalyst containing the conjunct polymer with the at least one borane compound. 